London-based drive systems GKN Automotive has created a ‘real-time’ test rig to meet unique requirements of electric vehicles.
The rig, installed at GKN Automotive’s Offenbach facility, can handle the extreme dynamics and higher torque of electrified powertrains, which make conventional load test rigs unsuitable for driveline parts of the latest generation, such as side shafts, the company said.
Explaining the rig’s working, the company said it can test specific load data provided by customers, from small electric city cars to the most powerful SUVs and is able to dynamically control speed and torque to replicate wheelspin and other complex driving conditions.
The company said it identified that a new testing regime would be required to replicate the different load characteristics of electric motors compared to those of conventional combustion engines, and analysed at an early stage how to design and engineer driveline products for EVs.
“Electric vehicles place different load dynamics on our driveline components and this new rig allows us to accurately reproduce those to achieve an unprecedented level of testing,” said Mario Syhre, Director Product Technology at GKN Automotive.
Components need to be much stronger to cope with the higher torque and the extra weight of EVs, without increasing significantly in size or weight, and remain as cost-effective as possible, Syhre said, adding the new rig allows them to accurately replicate the loads on the components and “deliver the lightest, most efficient solution”.
The rig meets the standards while minimising the weight of components and the amount of material used, thus it delivers significant sustainability improvements to GKN’s products, the company said. This results in enhanced EV efficiency and performance, highlighting the importance of the rig in our mission to drive a cleaner, more sustainable world, it added.